changing handlebars
Seasoned HDF Member
Joined: Jun 2006
Posts: 28,520
Likes: 3,953
From: Vermont
Several do it. Depends on what size you are going with if you need to change cables or not. Nothing real special for tools, torque wrench, torx bits, contact pin removal tool is handy but can be done with a paper clip or homemade tool
Seasoned HDF Member
Joined: Jun 2006
Posts: 28,520
Likes: 3,953
From: Vermont
To change the bars on a fairing model you have to remove the outer fairing, remove the ignition and switch cap and pull the radio out. If you need to change the clutch cable then you would have to drop the exhaust to get to the clutch release cover (tranny side cover) unless one has an 09 and later with stock exhaust then you can remove or loosen the heat shield to get to the bolts. There are also a few tricks along the way which can be found here on the forums
Last edited by dawg; Jul 12, 2010 at 01:41 PM.
Cruiser
Joined: Jan 2010
Posts: 209
Likes: 1
From: North Cackalacky
First poster was right, buy a manual and see if you have the skill set to replace the bars. It is a simple procedure if you are somewhat handy but everyone has a different level of comfort and your bars control where your bike goes. So make sure you are comfortable tooling around
Road Captain
Joined: Mar 2008
Posts: 569
Likes: 7
From: Massachusetts
Trending Topics
Novice
Joined: Jun 2010
Posts: 19
Likes: 0
From: new york
you need to take off the outer fairing and the fairing cap. to remove the cap you need to remove the ignition switch which is easy, but you will need a tool to turn the switch without the *** in place.you can make a tool out of copper tubing for this. there is another thread on how to make the tool. you also have to remove the radio. if you are puting on the harley pullback, W0575's or sweepers you will only have to change the clutch cable. the brake line and all other lines are ok. if you are internally wiring the bars then you will need a new TBW sensor which does not have the little green connector. if you are not going to internally wire the bars take the stock connector can be reused. I just did this job last week using the harley pullback bars.the whole job should take you no more than 4 hours. Do not listen to anyone about needing to remove the exhaust or heat shields to get at the clutch cover. you need to get two 3/16" standard 90 degree allen wrenches. on the shorter end of one of the wrenches cut off half the key. you need the wrenches to remove the two bottom bolts. use the long wrench to break the bolts loose, on use this wrench until it starts hitting the exhaust pipe then use the cut wrench to remove the bolts the rest of the way. believe me the cover comes off very easy using this method. also do not listen to anyone about not replacing the clutch cable or re-routing it. if you want the cable to go thru the fairing like stock you need to replace the cable. for an 08 and later use part number 38649-08 (cable 38649-98 for pre 07's or cable 38649-07 for 07's) its a 4 inch longer than stock harley cable its $34.00. you do not have to buy the diamond back cable like harley says for $99.00. overall its an easy job. Its a little tricking getting out the radio bolts because its a tight spot. 3/16 allen wrench works fine
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Road Captain
Joined: Mar 2009
Posts: 599
Likes: 1
From: Little Rock, Arkansas
Lots of good advise here. It would help if you had a service manual, the trickiest part is the key switch. It can all be done easily if you have patience (and cold beer). If you are uneasy about it, take pictures, especially of the wiring. Best advise, patience. You will like them even more because YOU did it.
Thread
Thread Starter
Forum
Replies
Last Post
